Reusable inflatable packaging device

ABSTRACT

A reusable packaging device that in a use state is a rhomboid outer structure with an internal inflatable and reusable vessel that surrounds and protects a payload, that can be converted into a storage state by deflating the vessel and folding the outer structure flat in order that it may be stacked.

PRIORITY CLAIM

This is a utility application that claims the benefit of U.S. Prov. Pat.App. No. 62/771,415 filed on Nov. 26, 2018 which is incorporated byreference in its entirety herein for all that it teaches.

FIELD OF INVENTION

This invention relates to devices used to package or encase merchandisefor shipment to customers.

BACKGROUND

The rise of the Internet has increased the practice of buying andselling goods remotely, where selection and purchase of goods may bedone on-line. This commercial activity has been growing at anexponential rate. In order to ship merchandise purchased on-line, theshipper typically houses the merchandise in a corrugate box filled withsome kind of shock absorbing filler. The popularity of ecommerce is adirect cause of skyrocketing use of corrugate boxes. This is anecological problem.

One third of the average landfill dump is packaging material. 69 Milliontons of paper and paperboard are used each year. Materials recycling isonly of limited value. While it is true that cardboard and corrugateboxes are recyclable, the fibers are only usable 11 times before thefibers are too weak to use. In any case, recycling of boxes places aburden on consumers: they have to break down and store the boxes inorder to place them out for pickup by local recycling services. Thereaction is often not to recycle at all. The current packagingexperience holds its fair share of frustrations. Once you receive apackage, especially a large one or one carrying fragile items, there isa mountain of “stuff” that the user needs to get rid of Including butnot limited to; styrofoam, packaging peanuts, packaging airbags,internal corrugate pieces and finally the entire corrugate box itself.The current packaging experience is both frustrating for the consumer,as well as environmentally damaging. Therefore, there is a need for afoldable, collapsible, stackable packaging system that the user couldcompress down to something flat and mail back to the sender forimmediate reuse.

DESCRIPTION OF THE FIGURES

The headings provided herein are for convenience only and do notnecessarily affect the scope or meaning of the claimed invention. In thedrawings, the same reference numbers and any acronyms identify elementsor acts with the same or similar structure or functionality for ease ofunderstanding and convenience. To easily identify the discussion of anyparticular element or act, the most significant digit or digits in areference number refer to the Figure number in which that element isfirst introduced (e.g., element 101 is first introduced and discussedwith respect to FIG. 1).

FIG. 1 is a cutaway view of the interior of the packaging system

FIG. 2 depicts the claimed invention in its relaxed state, and in itsinflated state as shown next to the air pump used to inflate

FIG. 3 is an exploded view of the packaging system

FIG. 4 depicts the claimed invention in a second embodiment

FIG. 5A-5E depicts the claimed invention in its relaxed, non-inflatedstate, where the user removes the package, deflates the package andreplaces the shipping label with a return receipt

FIG. 6 shows how the claimed invention is deflated and folded forfurther use, and further depicts the crease at the bottom of thepackaging system

FIG. 7A-7D depicts the steps of deflating, or collapsing, and foldingthe claimed invention

FIG. 8 is a drawing showing the claimed invention according to fourdifferent exploded or expanded perspectives

FIG. 9 is a model of the claimed invention depicting two heat sealedlayers with ribbing and the outer layer.

FIG. 10A-10C is a model of the claimed invention depicting the outerlayer and valve formed from the heat sealing of the two inner layers

FIG. 11A-11D is a model of the claimed invention depicting the layersthat are heat sealed and sewn

FIG. 12 is a depiction of an 8″×8″ square piece of jute

FIG. 13 is a depiction of the “stiffness test” as further set forth inthe specification

FIG. 14 shows is a further depiction of the “stiffness test” as furtherset forth in the specification

FIG. 15 is a depiction of the “corner test” as further set forth in thespecification.

FIG. 16 is a depiction of the “corner test” as further set forth in thespecification.

FIG. 17 is a depiction of the “corner test” as further set forth in thespecification.

FIG. 18 is a depiction of a 12.25″×21″ rectangular piece of jute

FIG. 19 is a depiction of a punch with a tetrahedron shape at one end

FIG. 20 is a depiction of one embodiment where the mylar inner wall isbeing punctured as further set forth in the specification

FIG. 21 is a depiction of one embodiment of the wall section of theinvention

FIG. 22 is a depiction of one embodiment of the wall section of theinvention

DETAILED DESCRIPTION

Various examples of the invention will now be described. The followingdescription provides specific details for a thorough understanding andenabling description of these examples. One skilled in the relevant artwill understand, however, that the invention may be practiced withoutmany of these details. Likewise, one skilled in the relevant art willalso understand that the invention can include many other features notdescribed in detail herein. Additionally, some well-known structures orfunctions may not be shown or described in detail below, so as to avoidunnecessarily obscuring the relevant description. The terminology usedbelow is to be interpreted in its broadest reasonable manner, eventhough it is being used in conjunction with a detailed description ofcertain specific examples of the invention. Indeed, certain terms mayeven be emphasized below; however, any terminology intended to beinterpreted in any restricted manner will be overtly and specificallydefined as such in this Detailed Description section.

The inflatable packaging is comprised of three layers, an outer layer(102), and one or more inner layers (103) that form an inflatable vesselor bladder. See FIG. 1. The interior vessel can include a metal coatedfilm, aluminum coated mylar and/or may be covered by a fourth,protective, textile layer. In the preferred embodiment, the inner twolayers are comprised of Mylar. When inflated, the inflated vesselstiffens the walls of the outer layer and provide structural support.The outer layer (101) material is made of a sufficiently flexiblematerial that becomes rigid in combination when the vessel is inflated.In one embodiment, outer layer is formed from a layer of material thatforms a rhomboid, with a bottom, four sides and a top. (FIG. 8). Theouter layer and vessel layers are formed from flat pieces that aresubstantially the same dimensions that fold in the same way to form arhomboid shape. The vessel layers are an inflatable device that in oneembodiment encircles the interior proximate to the four sides of therhomboid. In other embodiments, the vessel can be formed to be furtherproximate to the bottom or top (102) (or both) of the rhomboid.

The package is configured to be usable in two states. In a first state,the vessel is deflated and the bottom and two sides of the rhomboid areeach folded in on themselves with at least a bifold, in order thatpackaging device lay substantially flat, with the top laying over one ofthe sides. (FIG. 6). The folded configuration is flat, with the lid ofthe package folded over, and the bottom and two sides folded on itselfat the center of each panel in order that the device to be substantiallyflat and stackable. In the second state, the vessel is inflated, and thebottom and two sides of the rhomboid unfolded. In this state, thepackaging device is ready to receive a payload that is placed in itsinterior region. The vessel is further inflated until the vessel pressesagainst the payload. The top may then be closed and fastened. The outerlayer preferably has a transparent pouch attached to its exterior intowhich shipping labels may be inserted. (FIG. 5C-5E).

The outer layer top is attached along a first edge to a correspondingtop edge of one side of the rhomboid, such that the top may be open andclosed using that first edge as a hinge. (102) A fastener may beattached along the opposing edge from the first edge, for example afirst side of a zipper seam may be attached along the opposing edge andthe second side of the zipper seam may be sewn along the correspondingtop edge of the opposite side of the rhomboid from the side thatattaches the hinging first edge. In other embodiments, one side of azipper seam may be sewn along three edges of the top of the rhomboid,with mating side sewn along the corresponding three edges at the top ofthree sides of the rhomboid. The rhomboid itself may be a cube.

The material comprising the outer layer is selected of a sufficientlystiff material that resists penetration by corners of other boxes,especially cardboard or corrugate box corners. In other embodiments, theouter layer material is selected to be resistant to needle penetration.In the preferred embodiment, the outer layer is a textile comprised ofjute fibers. However, other embodiments include woven synthetic fibers.Both jute or synthetic fibers have high tenacity (breaking force), soundand heat insulation properties and low thermal conductivity. In thepreferred embodiment, the outer layer is a jute textile, with syntheticfibers comprising a hem sewn along the edges of the jute textile piecethat, when folded and sewn at the seams, forms the package. Materialsthat may be used as an outer layer include a stiff plastic, cardboard,corrugate, or a synthetic fiber textile. The material stiffness must besufficient to protect from puncture. In one embodiment, the sufficientstiffness resists puncture by the corners of other boxes that may besharing space in a truck or airplane. In other embodiments, the materialis sufficiently stiff so as to resist puncture by needles. For example,an embodiment may have an outer layer that resists a needle puncture upto a piercing by a force between 2 and 10 Newtons by a 25 gauge needlepenetrating perpendicular to the material.

In order to determine whether the material is sufficiently stiff so thatit resists penetration by corners of other boxes, the following test, asdepicted in FIGS. 12-14, may be performed. An exemplary embodiment isexplained in further detail as follows:

-   -   1) Placing an 8″×8″ square piece of jute on the edge of a rigid        wooden board. See FIG. 12, where the piece is placed such that        exactly half of it is off the edge of the board—4″ off the edge,        and 4″ still on the surface of the board. See FIG. 13.    -   2) The 4″ half that remains on the wooden surface is held in        place by two pieces of tape—one on each corner—between the jute        and the wooden board. See FIG. 13.    -   3) The vertical distance between the edge of the jute furthest        from the wooden board and the horizontal plane of the wooden        board is measured, where in the preferred embodiment, the        measurement is 1.75″; (See FIG. 14), resulting in a stiffness of        about 44%, calculated by dividing the vertical distance of the        edge that drops down because of gravity by the distance out from        the edge of the test bench.    -   4) In alternative embodiments, this value for stiffness may        range from around 33% to around 73%.    -   5) In yet another embodiment, for some applications this value        of stiffness is greater than 73%.

The inner layers can be made of any thin, flexible material, including,but not limited to; mylar, polyethylene based plastics, pulp basedfibers, aluminum foil, rubber, or latex, that may be sealed to form anairtight but flexible chamber. Some of these materials may be morepuncture proof than the others. Regardless of material, the inner layersmay also be coated in a polyurethane based compound to provide increasedpuncture resistance. In a preferred embodiment, the material will bemylar. A 200 gauge (0.002″) mylar layer specifically has a punctureresistance of around 12 lbf (pound force, 1 lbf≈4.448222 N)—however itcan range from 10 lbf-22 lbf. Layers of between 100 and 300 gauge mylarmay be sufficient for some applications. In other applications, thepuncture resistance of the inner layer has to be more than 22 lbf.

In order to determine whether the material is sufficiently punctureresistant so as to resist puncture by corners, the following test, asdepictured in FIGS. 15-19, may be performed. An exemplary embodiment isexplained in further detail as follows:

-   -   1) Placing a 12.25″×21″ rectangular piece of jute (reinforced on        the edges with fabric) pulled taught and centered over two        vertical wooden boards spaced 12″ apart (outside edge to outside        edge). See FIG. 15.    -   2) Where the jute is pulled such that the ends of the piece of        jute around the edges and clamp to the sides of each board. See        FIG. 15 where there is one clamp placed at each corner of the        piece of jute.    -   3) Thereafter, using a punch with a tetrahedron shape at one        end, with the corners of the point meeting at 45 degree angles        (to mimic the corner of a rectangular box). FIG. 19.    -   4) Pressing the punch into the center of the taut piece of jute        with its center axis directly vertical or perpendicular to the        flat piece of jute. FIG. 16, 17.    -   5) Measuring the force (in pounds) for the punch to puncture the        jute, where, in one embodiment, puncture occurred between 18-22        pounds of pressure.    -   6) In alternative embodiments, puncture occurs between 10 and 25        pounds of pressure.    -   7) In yet another embodiment, puncture occurs at at least 10        lbf.

In yet another embodiment, the following test, as depicted in FIG. 20 isperformed:

-   -   1) A 12.25″×21″ rectangular piece of jute (reinforced on the        edges with fabric) and a 12.25″×21″ rectangular piece of mylar        are aligned directly on top of each other and pulled taught and        centered over two vertical wooden boards spaced 12″ apart        (outside edge to outside edge).    -   2) The ends of the pieces of jute and mylar are pulled around        the edges and clamped to the sides of each board, where one        clamp is placed at each corner of the piece of jute and mylar.    -   3) Using a punch with a tetrahedron shape at one end, with the        corners of the point meeting at 45 degree angles, the punch is        pressed into the center of the taut piece of jute and mylar (the        punch hit the jute first then the mylar) with its center axis        directly vertical or perpendicular to the flat piece of jute.    -   4) Measure the force (in pounds) it takes for the punch to        puncture the jute AND mylar.    -   5) In said embodiment, the puncture occurred between 25-40        pounds of pressure.    -   6) In alternative embodiments, the puncture occurs at at least        25 pounds of pressure.

The reason the puncture resistance is high is that there is airspacebetween the mylar and the jute, and the mylar has some give to it (seeFIGS. 20-22). When the punch punctures the jute, it then pushes themylar wall another inch or so before it punctured the mylar (see FIG.20.).

The vessel is an air-tight compartment that is formed of a flexiblematerial such that when deflated, it occupies little volume, but whenfully inflated occupies substantially all of the interior region of thepackaging device. See FIG. 2. This makes it possible to have a one-sizefits all device, in that a payload that is smaller than the interiorregion of the packaging device is inserted into the interior and isprotected by inflating the vessel until the payload is secure—whateverits size.

In the preferred embodiment, the vessel is comprised of ribs along theinterior surface of the vessel (901) in order to prevent the walls ofthe outer layer from being appreciably deformed or rounded when thevessel is inflated. See FIG. 9.

The ribbed vessels may be comprised of textile enforced plastic, ormylar, however, the former permits a higher pressure load. In thepreferred embodiment, the vessel is formed of two layers of mylar. Thetwo inner layers that form the vessel are made of Mylar film—which is ahigh tensile strength plastic that forms a gas tight and odor barrier.Multiple sheets of Mylar may be melted and sealed together under hightemperatures, referred to herein as heat sealing. A heat susceptibleplastic layer may be used such that heat sealing or heat forming of ribsor creases may be accomplished. In addition, the vessel may be furthercomprised of a textile later that covers at least the interior layer ofthe plastic in order that the package payload not directly chafe orpuncture the plastic layer forming the vessel itself. This textile layermay be of a sufficient strength to be resistant to corner punctures orneedle punctures. See FIG. 20.

The vessel is made as one inflatable component, rectangular in overallshape, the width of which is the height of the rhomboid and the lengthof which is the perimeter of the top or bottom side of the rhomboid. Thevessel is comprised of ribs that, when fitted into the box, are parallelto the plane of the lid and floor. The vessel is further formed withdepressions running along the widths are points such that when fittedinto the box, the depressions are situated at the corners of the box,occupying the region along the four vertical corners of the rhomboid.

The two layers of mylar that form the vessel are heat sealed around theedges. Within that heat seal, the vessel is then sewn into the outertextile layer forming the outer layer. See FIG. 11. The heat sealforming the vessel is along the perimeter of the top and bottom and sewnalong those perimeters to the outer layer.

The ribs are formed by using the heat sealing device to sufficientlyheat the mylar so as to distort it along the desired orientation of therib line but not to actually seal the two layers of mylar on eitherside. The result is a defined crease in the interior layer, referred toas the rib. Creases in the vessel are also formed along the line thatforms the vertical corners of the rhomboids. There are pre-defined linesthat form three vertical corners where heat is applied on both theexterior side of the vessel and interior of the vessel in order that thecorner be well defined, but the interior and exterior layers arepreferably not sealed together.

In one embodiment of the invention, the vessel is formed from tworectangular sheets of mylar. The vessel thus formed is attached to beproximate to the four sides of the rhomboid. In other embodiments, thetwo sheets of mylar are “T” shaped. Additional corner creases areapplied such that one arm of the “T” can be placed proximate to thebottom of the rhomboid and the other arm proximate to the top or lid ofthe rhomboid. The creases are formed where the edge of the bottom meetsone of the sides of the rhomboid and where the edge of the top meets theside of the rhomboid. In this embodiment, the vessel can be inflated soas to push against the payload in 6 directions.

The vessel is further comprised of a valve that can selectably be usedto inflate or deflate the vessel. In another embodiment, the valve forthe inner vessel unit is incorporated into the invention by way of aninflatable valve technology using mylar components cut or shaped out ofthe mylar sheets or a separate valve system. The valve is comprised of astandard attachment into which a pressurizing device may be connected,for example an air pump. Further, the valve can be operated so as thepressure in the vessel is released in order that it be deflated. In oneembodiment, the valve comprised of the mylar layers comprising thevessel itself. See FIG. 10a -c. For example, the mylar layers may beshaped so that upon heat sealing of the two layers, a valve stem iscreated. Further, the mylar may be folded internally to the stem regionin order to form a valve, such that when pressure is created on theinterior of the vessel, the pressure forces a flap of mylar within thevalve stem to remain closed. Further, the flap is movable by means of aforeign object inserted into the valve stem in order to move itsposition and deflate the vessel. In this way, the valve itself is fullyintegrated with the vessel—the two layers with some added technologyform the valve. By being integrated using the mylar layer, the valvestem and valve folds flat when not in use, whether the package is in thefolded state or the inflated state with the lid or top closed. The valveitself is comprised of two halves, where each half comprises itsrespective half of the entire inner vessel. The interior walls of thevessel and interior half of the valve all comprise one sheet. Theexterior walls of the vessel and exterior half of the valve will allcomprise one sheet. See FIG. 3. In this latter embodiment, the two mylarlayers forming the vessel will have a stem potion that when heat-sealedtogether comprise the valve.

In alternative embodiments, the valve may be comprised of bike valvestems, a Boston Valve, a Silicone Medical Resuscitator Intake UmbrellaValve, a silicon respirator valve, or a rubber ball inflation valve—anyof which may be attached via heat sealing; welding or adhesives at thebase or the brim of any of the aforementioned types of valves.

In an alternative embodiment, the vessel may be attached at verticalcorners using an adhesive. Further, an adhesive may bond the vessel tothe outer layer. The vessel is then configured so that as it inflates,each portion of the vessel corresponding to each side of the rhomboidexpands primarily at the center, so as to form, in cross section, anarc, where the maximum point of expansion is at the center of thepolygon formed by the corresponding side of the rhomboid. See FIG. 4.

In yet another alternative, instead of one contiguous vessel comprisingthe package, there may be more than one vessel within the package, eachinflated individually. In another embodiment, each panel comprising thesides, top and bottom of the rhomboid may have a vessel attached to itthat has its own valve, the vessels being configured such that whenfully inflated together, the vessels together occupy substantially allof the interior of the rhomboid.

The foregoing description discloses only exemplary embodiments of theinvention. Modifications of the above disclosed apparatus and methodswhich fall within the scope of the invention will be readily apparent tothose of ordinary skill in the art. Accordingly, while the presentinvention has been disclosed in connection with exemplary embodimentsthereof, it should be understood that other embodiments may fall withinthe spirit and scope of the invention as defined by the followingclaims.

What is claimed:
 1. An inflatable packaging device that is adapted in afirst state to be folded in a substantially flat configuration and in asecond state, to be expanded and inflated to enclose and protect anarticle, said packaging device comprising: An outer layer material thatin the second state forms a rhomboid with four sides, a bottom and a topand an interior region; An inflatable vessel comprised of at least oneinner layer material, said vessel inside the interior region placed inproximity to at least the interior four sides of the rhomboid, saidvessel expandable so as to occupy substantially all of the interiorregion when the vessel is inflated without a payload, withoutappreciably deforming the outer layer rhomboid shape; A valve attachedto the vessel, said valve operable to selectively admit air underpressure in order to expand the vessel or release air from the vessel inorder to compact the vessel.
 2. Claim 1 where the vessel is comprised ofa region that is proximate to the bottom of the rhomboid.
 3. Claim 2where the vessel is further comprised of a region that is proximate tothe top of the rhomboid.
 4. Claim 1 where the vessel is comprised of aflexible plastic membrane layer,
 5. Claim 4 where the plastic layer isfurther covered in a textile material layer.
 6. Claim 1 where vessel iscomprised of textile reinforced plastic material
 7. Claim 1 where thevessel is comprised of mylar.
 8. Claim 1 where the vessel is comprisedof ribs that retard the local dimension of expansion in order that thevessel not appreciably distort the rhomboid shape.
 9. Claim 1 where thevessel is comprised of corner lines that that retard the local dimensionof expansion in order that the expansion of the vessel into the interiorregion is primarily at the center line of each side of the rhomboid. 10.Claim 1 where the exterior layer is jute.
 11. Claim 1 further comprisingan insulating layer between the outer layer and the vessel.
 12. Claim 11where the insulating layer is a metallic coated plastic.
 13. Claim 12where the plastic is mylar.
 14. Claim 1 where the packaging device isconfigurable into a second state, where the vessel is deflated, thebottom of the rhomboid folded onto itself with at least a single bifold,at least two sides of the rhomboid are folded onto themselves with atleast a single bifold and the top of the rhomboid is attached to thesides along a seam with one of the sides, and folded over the sides inorder that the device is substantially flat.
 15. Claim 1 where thevessel is comprised of mylar.
 16. Claim 15 where the mylar is formed bytwo sheets of mylar that are heat sealed along the edges.
 17. Claim 1where the vessel is formed of a heat-susceptible plastic and furthercomprised at least one heat-formed rib crease placed on the interiorsurface of the vessel and placed in a plane parallel to the bottom ofthe rhomboid.
 18. Claim 1 where the vessel is formed of aheat-susceptible plastic and further comprised of at least oneheat-formed crease on at least one interior and corresponding exteriorcorner of the vessel.
 19. Claim 1 where the valve is formed of thematerial comprising the vessel.
 20. Claim 16 where the vessel isattached to the box by a seam sewn through the heat seal along theperimeter of the top or the bottom.
 21. The packaging device of claim 1where the outer layer material has a stiffness of between around 33% toaround 73%.
 22. The packaging device of claim 1 where the inner layer iscomprised of between 100 and 300 gauge mylar.
 23. The packaging deviceof claim 1 where the inner layer material has needle puncture resistanceof between 2 and 10 Newtons using a 25 gauge needle penetratingperpendicular to the material.
 24. The packaging device of claim 1 wherethe inner layer material has a corner puncture resistance of between 10lbf-22 lbf.
 25. The packaging device of claim 1 where the outer layermaterial has a corner puncture resistance of between 18 to 22 pounds.26. The packaging device of claim 1 where the outer layer material has acorner puncture resistance of between 10 to 25 pounds.
 27. The packagingdevice of claim 1 where the outer layer in combination with the innerlayer has a corner puncture resistance of between 25 and 40 pounds. 28.The packaging device of claim 1 where the stiffness is equal to orgreater than 73%.
 29. The packaging device of claim 1 where the outerlayer material has a corner puncture resistance equal to or greater than10 lbf.
 30. The packaging device of claim 1 where the outer layer incombination with the inner layer has a corner puncture resistance equalto or greater than 25 lbf.
 31. The packaging device of claim 1 where theinner layer material has a corner puncture resistance equal to orgreater than 22 lbf.
 32. The packaging device of claim 1 where the innervessel is covered in a textile fabric.
 33. The packaging device of claim1 where the inner layer of the inner vessel that is proximate to theouter wall is attached only along at least part of the perimeter of thecorresponding side of the outer layer.